hinge JEEP CHEROKEE 1995 Service Owner's Manual

(3) Align the trim panel retainers with the holes in
the liftgate inner panel and force the trim panel in-
ward.
(4) Install the screws to attach the panel upper
sides to the liftgate.
LIFTGATE HINGEÐXJ
REMOVAL
It is not necessary to remove the liftgate to replace
one or both hinges.
(1) Remove the liftgate (headliner) upper trim
molding (Fig. 7).
(2) Remove the hinge-to-roof panel nuts (Fig. 8).
(3) Remove the hinge-to-liftgate screws and remove
the hinge from the liftgate (Fig. 9).
INSTALLATION
(1) Position the gaskets, shim and hinge on the
liftgate and the roof panel (Fig. 10).
(2) Install and tighten hinge-to-roof panel nuts to 9
Nzm (7 ft-lbs) torque.(3) Install the liftgate-to-hinge screws. Tighten
screws to 9 Nzm (7 ft-lbs) torque.
(4) Install the liftgate (headliner) upper trim mold-
ing (Fig. 7).
Fig. 7 Liftgate Upper Trim Molding
Fig. 8 Liftgate Hinge-To-Roof Panel Nuts
Fig. 9 Liftgate Hinges
Fig. 10 Liftgate Hinge, Gaskets and Shim
23 - 60 DOORSÐXJJ

LIFTGATE SUPPORT ROD CYLINDER DISPOSALÐ
XJ
WARNING: SAFETY GOGGLES MUST BE WORN
DURING THE DISPOSAL PROCEDURE. THE HIGH
PRESSURE GAS CHARGE IN THE SUPPORT ROD
CYLINDERS WILL BE RELEASED DURING THE
PROCEDURE.
(1) Remove the support rod cylinder(s) from the
liftgate.
(2) Position the support rod cylinder horizontally
in a vise and clamp the cylinder securely.
(3) Wrap the cylinder with 4-5 layers of shop tow-
els.
(4) Measure 1 and 1/2 inches inward from the end
of the cylinder. Mark this location on the towels with
chalk. The cylinder will be punctured at this location
to release the gas charge.
(5) Use a punch and hammer to puncture cylinder.
Force the punch through towels and into the cylinder
with a hammer. Continue striking the punch until
the gas begins to escapebut do not remove the
punch.
(6) Hold the towels and punch in position until all
the gas has escaped. Complete de-pressurization will
require about 4 to 10 seconds. After all the gas has
escaped, slowly remove the punch.
(7) Hold a towel over the hole in cylinder and press
the support rod piston all the way into the cylinder
to purge remaining oil.
(8) Remove the support rod cylinder from the vise
and discard it.
(9) If both support rod cylinders are being re-
placed, repeat this procedure for the remaining cylin-
der.
LIFTGATE SUPPORT ROD BALL STUD
REPLACEMENTÐXJ
REMOVAL
(1) Open the liftgate.
(2) Support the liftgate in the open position.
(3) Remove the retainer clip that attaches the sup-
port rod and cylinder to the ball stud.
(4) Disconnect the support rod from the ball stud.
(5) Remove the ball stud from the liftgate with a
T-30 Torx-head socket wrench (Fig. 3).
INSTALLATION
(1) Install the replacement ball stud in the liftgate
with a T-30 Torx-head socket wrench. Tighten the
ball stud to 7 Nzm (62 in-lbs) torque.
(2) Connect the support rod to the ball stud.
(3) Secure the support rod to the ball stud with the
clip.
(4) Remove the support from the liftgate and test
the operation of support rod.
LIFTGATE ADJUSTMENTÐXJ
SERVICE INFORMATION
The position of the liftgate can be adjusted upward
or downward, and inward or outward by the use of
hinge shims. The liftgate stop bumpers must also be
adjusted if liftgate hinges are adjusted. The inward/
outward position of each stop bumper is adjusted by
the use of shims (Fig. 4).
ADJUSTMENT PROCEDURE
(1) To move the position of the liftgate inward or
outward, remove or add shims between the hinge-
halves and liftgate.
(2) To move the position of the liftgate upward or
downward, remove or add shims between the hinge-
halves and roof panel.
Fig. 2 Support Rod, Retainer Clips and Ball Studs
Fig. 3 Support Rod Ball Studs
JDOORSÐXJ 23 - 63

REAR QUARTER VENT WINDOW GLASSÐXJ
REMOVAL
(1) Remove the vent window handle retaining pin
and nut (Fig. 8).
(2) Remove the hinge-to-glass screws and remove
the window glass. If glass adheres to the hinges, re-
move the glass by carefully pushing out hinge screw
inserts.
INSTALLATION
(1) Position the vent window glass at the hinges
and install the screws.
(2) Install the handle, pin and nut (Fig. 8).
(3) Test the vent window for water leaks.
REAR QUARTER WINDOW GLASS/REAR QUARTER
PLASTIC INSERTÐXJ
REMOVAL
(1) If equipped, remove the quarter window reveal
molding (Fig. 9).
(2)
Remove the quarter window interior trim covers.
(3) Separate the weatherstrip seal lip from the
window opening flanges. Use a pry tool and carefully
push the window glass and seal outward.
(4) Remove the weatherstrip seal and window
glass from window opening.
(5) Remove the weatherstrip seal from the window
glass.
INSTALLATION
(1) Clean the original sealant from the weather-
strip channels and window opening flanges.
(2) Apply a 4-mm (1/6-in) diameter bead of sealant
to the window channel in the weatherstrip seal.
(3) Install the weatherstrip on the window glass.
Install the seal installation cord in the window open-
ing flange channel as follows:
Fig. 8 Vent Window Handle Removal/Installation
Fig. 9 Quarter Window Reveal Molding, Glass and Seal
JSTATIONARY WINDOW GLASSÐXJ 23 - 731995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

EXTERIOR COMPONENTS
INDEX
page page
Battery TrayÐYJ......................... 110
Body Side Step MoldingÐYJ................ 115
Body Stripes/DecalsÐYJ................... 116
Cowl Grille and ScreenÐYJ................ 109
Cowl Weatherstrip SealÐYJ................ 109
Exterior Nameplates (Adhesive-Backed)ÐYJ.... 120
External Spare/Wheel Tire CarrierÐYJ........ 133
Fender FlareÐYJ........................ 114
Fender Inner Splash ShieldsÐYJ............. 116
Fender Splash ApronsÐYJ................. 115
FendersÐYJ............................ 110
Fuel Filler Protector/NozzleÐYJ............. 121
Half Metal Door Mirror (External)ÐYJ......... 121
Hard Top Liftgate GlassÐYJ................ 124
Hard Top RepairÐYJ..................... 127
Hard Top Roof VentÐYJ................... 127
Hard TopÐYJ........................... 126Hood AlignmentÐYJ...................... 107
Hood Insulator PanelÐYJ.................. 107
Hood Safety LatchÐYJ.................... 109
HoodÐYJ.............................. 107
Liftgate Glass Weatherstrip Seal ReplacementÐYJ. 125
Radiator Grille AppliqueÐYJ................ 104
Soft Top Service InformationÐYJ............. 127
Soft Top ServiceÐYJ..................... 129
Sport BarÐYJ........................... 132
Tailgate AdjustmentÐYJ................... 121
Tailgate HingeÐYJ....................... 121
Tailgate Latch and Release HandleÐYJ........ 122
Tailgate Latch StrikerÐYJ.................. 123
Tailgate Lock CylinderÐYJ................. 122
Tailgate Weatherstrip SealÐYJ.............. 123
TailgateÐYJ............................ 121
Wheelhouse Splash LinersÐYJ.............. 115
RADIATOR GRILLE APPLIQUEÐYJ
REMOVAL
(1) Raise the hood.
(2) Remove the headlamp bezels (Fig. 1).(3) Remove the headlamp bulb retainer screws
(Fig. 2).
(4) Disconnect and remove the headlamps and
buckets as a unit (Fig. 2).
Fig. 1 Grille Applique, Headlamp Bezel and Grille Panel
23 - 104 EXTERIOR COMPONENTSÐYJJ

INSTALLATION
(1) Position the grille panel on the vehicle.
(2) Connect the marker, park and headlamp wire
harness connectors.
(3) Connect the radiator support rods with the re-
taining brackets (Fig. 9).
(4) Attach the grille panel to the front crossmem-
ber.
(5) Install the grille panel-to-front fender bolts
(Fig. 7). Tighten the retaining screws to 27 Nzm (20
ft-lbs) torque.
(6) Install the air intake adapters on the grille
panel (Fig. 6). Tighten the retaining screws to 3 Nzm
(25 in-lbs) torque.
(7) Install the P/S fluid reservoir on the grille
panel (Fig. 5). Tighten the retaining screws to 8 Nzm
(72 in-lbs) torque.
(8) If equipped, install the A/C condenser on the
grille panel (Fig. 4). Tighten the retaining screws to 2
Nzm (20 in-lbs) torque. Connect the high pressure
hose at the sight glass connection and at the com-
pressor.
(9) Install the radiator and shroud on the grille
panel (Fig. 3). Tighten the retaining screws to 15
Nzm (132 in-lbs) torque.
(10) Install the front crossmember cover.
(11) If removed, install the grille applique (Fig. 8).
(12) Evacuate and charge the A/C system.
HOODÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Disconnect the underhood lamp wire harness
connector (Fig. 10).(3) Mark the position of the hinges on the hood for
installation alignment reference (Fig. 11).
(4) Remove the hinge attaching screws and remove
the hood (Fig. 11).
(5) If the hood must be replaced, remove and
transfer the insulator panel, hinges, latches,
bumpers, brackets, footman loop, hood lamp, support
rod, and safety latch to the replacement hood (Fig.
12).
INSTALLATION
(1) Position the hood on the vehicle and install the
hinge attaching screws.
(2) Align the hinges with the installation reference
marks on the hood and tighten the hinge screws se-
curely.
(3) Connect the underhood lamp wire harness con-
nector (Fig. 10).
(4) Close the hood.
HOOD ALIGNMENTÐYJ
The hood hinge attaching screw holes are oversized
to facilitate hood adjustment movement.
(1) Loosen the hinge attaching screws.
(2) Move the hood in the direction(s) required for
correct alignment.
(3) Tighten the hinge attaching screws.
HOOD INSULATOR PANELÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Remove the insulator panel retainers (Fig. 13).
(3) Remove the insulator panel from the hood.
INSTALLATION
(1) Position the insulator panel on the hood.
(2) Install the insulator panel retainers.
(3) Remove the support rod and close the hood.
Fig. 9 Radiator Support Rods
Fig. 10 Underhood Lamp
JEXTERIOR COMPONENTSÐYJ 23 - 107

BODY PANEL SURFACE PREPARATION
(1) The area that will be covered by the tape
stripe/decal must be cleaned with an cleaning solu-
tion to remove any residue paint.
(2) Freshly painted surfaces must be thoroughly
dry.
(3) Clean painted surface with a commercial wax
and silicone removal solution. Wipe surface with a
clean cloth and allow to dry.
REPLACEMENT ON ONE PANEL
For large tape stripes/decals, use a clean sponge
and apply ample wetting solution to the adhesive
side of the tape stripe/decal, and to the painted panel
surface.
The wetting solution will permit ease of tape
stripe/decal movement when positioning it on the
panel.
(1) Align a straight edge with the existing tape
stripe/decal ends and use a wax pencil to mark a line
on the panel (Fig. 5).If applicable, the body panel character line
can be used as the tape stripe/decal alignment
reference.
(2) Position tape stripe/decal and carrier on panel
and mark the required length with a wax pencil.
(3) Cut the stripe/decal and carrier at the required
length with scissors.
(4) Position stripe/decal and carrier on panel and
hold it in-place with pieces masking tape (Fig. 6).
(5) Lift the bottom edge of the tape stripe/decal
and carrier, use the tape sections as hinges, and re-
verse the position of the stripe/decal and carrier (Fig.
7).
CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from the carrier.
(6) Bend a corner of the carrier outward, separate
the corner of the carrier from the tape stripe/decal.
(7) Separate approximately 15 cm (6 in) of the car-
rier from one end of the tape stripe/decal (Fig. 8).
Fig. 3 Body Stripe/Decal Removal With A Squeegee
Fig. 4 Adhesive Removal With A Squeegee
Fig. 5 Stripe/Decal Alignment Reference Mark
Fig. 6 Tape Stripe/Decal and Carrier Retained On
Body Panel
23 - 118 EXTERIOR COMPONENTSÐYJJ

(3) Position the replacement nameplate on the
panel and apply inward force to seat it.
FUEL FILLER PROTECTOR/NOZZLEÐYJ
REMOVAL
(1) Either remove it or support the license plate
bracket away from the fuel filler protector and nozzle
(Fig. 1).
(2) Remove the cap from the nozzle.
(3) Loosen the clamps at the nozzle and separate
the hoses from the nozzle.
(4) Remove the screws that attach the protector to
the body panel.
(5) Remove the protector and nozzle from the open-
ing in the body.
(6) Remove the screws and separate the nozzle
from the protector (Fig. 1).
INSTALLATION
(1) Position the fuel filler nozzle on the protector
and install screws. Tighten the screws to 2 Nzm (20
in-lbs) torque.
(2) Position the protector and the nozzle in body
panel opening, and install. Tighten the screws to 3
Nzm (25 in-lbs) torque.
(3) Attach the hoses to the tubes and tighten the
clamp screws to 3 Nzm (30 in-lbs) torque.
(4) Install the cap on the nozzle.
(5) If removed, install the license plate bracket.
HALF METAL DOOR MIRROR (EXTERNAL)ÐYJ
REMOVAL
(1) Remove the mirror base attaching screws from
the door hinge (Fig. 2).
(2) Remove the mirror from the door hinge (Fig. 2).
INSTALLATION
(1) Clean the door hinge-mirror base contact sur-
face.
(2) Position the mirror base at the door hinge.
(3) Install the mirror base attaching screws in the
door hinge. Tighten the attaching screws to 11 Nzm
(96 in-lbs) torque.
TAILGATEÐYJ
REMOVAL
(1) Remove the tailgate hinge screws with a Torx
bit (Fig. 3).
(3) Disengage the latch and remove the tailgate
from the vehicle.
INSTALLATION
(1) Position and align the tailgate in the body
opening and engage the latch.
(2) Install the hinge retaining screws. Tighten the
screws to 18 Nzm (156 in-lbs) torque.
TAILGATE HINGEÐYJ
REPLACEMENT
(1) Remove the hinge retaining screws and remove
the hinge (Fig. 3).
(2) Prepare and paint the replacement hinge to
match the body paint color.
(3) Lubricate the hinge with spray lubricant.
(4) Position the hinge on the body and install the
retaining screws (Fig. 3). Tighten the screws to 18
Nzm (156 in-lbs) torque.
(5) Align the tailgate with the hinge and install
the hinge-to-tailgate screws. Tighten the screws to 18
Nzm (156 in-lbs) torque.
TAILGATE ADJUSTMENTÐYJ
(1) Loosen the tailgate hinge-to-body screws (Fig.
3).
Fig. 1 Fuel Filler Cap, Protector, Nozzle and Hoses
Fig. 2 Half Metal Door Mirror
JEXTERIOR COMPONENTSÐYJ 23 - 121

(2) Align the tailgate in the body opening and
tighten the hinge screws to 18 Nzm (156 in-lbs)
torque.
TAILGATE LATCH AND RELEASE HANDLEÐYJ
REMOVAL
(1) Open the tailgate and remove the latch trim
cover (Fig. 3).
(2) Remove the tailgate latch-to-handle rod re-
tainer and disconnect the rod from the latch (Fig. 3).
(3) Remove the latch-to-tailgate screws (Fig. 3).
(4) Remove the retainer clip from the latch-to-lock
cylinder rod and disconnect the rod from the lock cyl-
inder (Fig. 4).(5) Remove the retainer clip from the latch-to-re-
lease handle rod and disconnect the rod from the re-
lease handle (Fig. 4).
(6) Remove the latch from the tailgate.
(7) Remove the latch release handle screws.
(8) Remove the release handle and seal from the
tailgate.
INSTALLATION
(1) Position seal latch release handle on the tail-
gate and install screws. Tighten the screws to 6 Nzm
(50 in-lbs) torque.
(2) Position the latch at the tailgate.
(3) Install the latch retaining screws and connect
the latch rods and rod retainers (Fig. 4 and 5).
Tighten the screws to 6 Nzm (50 in-lbs) torque.
(4) Install the latch cover. Tighten the screws to 11
Nzm (96 in-lbs) torque.
TAILGATE LOCK CYLINDERÐYJ
REMOVAL
(1) Open the tailgate.
(2) Remove the latch cover.
(3) Remove the lock cylinder retainer clip (Fig. 6).
(4) Disengage the lock cylinder lever (Fig. 6) from
the latch-to-lock cylinder rod.
(5) Remove the lock cylinder from the tailgate
opening.
(6) Remove the E-clip and separate the lever from
the lock cylinder (Fig. 6).
Fig. 3 Tailgate and Components
Fig. 4 Tailgate Latch and Rods
23 - 122 EXTERIOR COMPONENTSÐYJJ

HARD TOP LIFTGATE GLASSÐYJ
REMOVAL
(1) Disconnect the rear defroster/dome lamp wire
harness connectors.
(2) Remove the wiper motor cover. Disconnect the
wiper motor wire harness connector and the washer
fluid hose (Fig. 1).
(3) Remove the wiper arm and blade (Fig. 1).
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE SUP-PORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL IN-
JURY AND/OR VEHICLE DAMAGE IF THEY ARE RE-
MOVED WITH THE PISTONS COMPRESSED (LIFTGATE
CLOSED). ONCE REMOVED, DO NOT ATTEMPT TO
DISASSEMBLE OR REPAIR THE SUPPORT RODS.
(4) Open the tailgate (Fig. 2).
(5) Remove the support rod cylinder retaining clips
at both ends of each support rod cylinder (Fig. 2)
(6) Pull the support rods off the ball studs.
(7) Remove the liftgate glass hinge bolts (Fig. 2).
Fig. 1 Liftgate Wiper Motor
Fig. 2 Liftgate Removal/Installation
Fig. 8 Tailgate Weatherstrip Seal Removal/Installation
23 - 124 EXTERIOR COMPONENTSÐYJJ

(8) Separate the liftgate glass from the hard top.
(9) Remove the weatherstrip seal (Fig. 2), if neces-
sary.
INSTALLATION
(1) Assemble the liftgate components, if necessary
(2) Position the liftgate glass in the hard top open-
ing and install the hinge bolts. Do not tighten the
bolts.
(3) Adjust the liftgate glass to fit the hard top
opening.
(4) Tighten the hinge bolts to 11 Nzm (95 in-lbs)
torque.
(5) Position the support rod cylinders on the ball
studs.
(6) Install the support rod cylinder retainer clips.
(7) Connect the wiper motor wire harness connec-
tor and the washer fluid hose. Install the wiper mo-
tor cover (Fig. 1).
(8) Install the wiper arm and blade.
(9) Connect the rear window defroster/dome lamp
wire harness connectors.
DISASSEMBLY
(1) Remove retaining screws and the lower, inner
trim molding from the latch panel (Fig. 3).
(2) Remove the retaining screws and the latch
panel, inner gasket, outer gasket, and the lower,
outer liftgate molding from the liftgate (Fig. 3).
(3) Refer to Group 8, Electrical for service informa-
tion involving the wiper motor and the defroster.
(4) If necessary, remove the latch strikers and the
ball stud brackets from the hard top inner panel (Fig.
3).
ASSEMBLY
(1) If removed, install the latch strikers and the
ball stud brackets on the hard top inner panel (Fig.
3).(2) Position the latch panel, and gaskets, and lift-
gate molding on liftgate and install screws (Fig. 3).
Tighten the screws to 7 Nzm (60 in-lbs) torque.
(3) Position the lower, inner trim molding on the
latch panel. Install screws (Fig. 3). Tighten the
screws to 2 Nzm (12 in-lbs) torque.
LIFTGATE GLASS WEATHERSTRIP SEAL
REPLACEMENTÐYJ
REMOVAL
(1) Remove the liftgate glass from the hard top. If
necessary, refer to the removal procedure.
(2) Remove the retaining screws from the liftgate-
to-tailgate weatherstrip seal (Fig. 4).
(3) Carefully separate the seal and retainers from
the bottom of the liftgate glass.
(4) Remove the hard top weatherstrip seal retain-
ing screws from body rear panels.
(5) Carefully separate the weatherstrip seal from
the rear panels and the hard top.
(6) Remove the residual adhesive from the seal
contact areas.
INSTALLATION
(1) Remove the tape cover and position the liftgate-
to-tailgate weatherstrip seal at the bottom of the lift-
gate glass (Fig. 4).
(2) Carefully insert the retainers into the holes
and press the seal against the bottom of the liftgate
glass.
(3) Install the liftgate-to-tailgate weatherstrip seal
screws Tighten the screws securely.
Fig. 3 Liftgate and Components
Fig. 4 Liftgate Glass Weatherstrip Seals
JEXTERIOR COMPONENTSÐYJ 23 - 125